Intake Manifold: Removing

WARNING: This page is about a different car, the 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, 2009 Audi S5, and 2008 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .
Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

NOTE:

All Cable Ties Opened Or Cut During Engine Removal Must Be Reinstalled At The Same Locations During Installation.

-- With ignition switched off, disconnect Battery Ground (GND) cable.

-- Remove engine cover.

-- Pull the cover -1- forward and remove it upward.

Fig 1: Identifying Cover -1-

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-- Disconnect the connector -1- and disconnect the vacuum lines -arrows-.

Fig 2: Identifying Connector -1- And Vacuum Lines -Arrows-

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-- Remove vacuum line -4- at air guide hose.

Fig 3: Identifying Vacuum Line, Air Guide Hose, Crankcase Ventilation Hose & Hose Clamps

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NOTE:

Ignore -1-.

-- Lay aside air guide hose with connected crankcase ventilation hose -3- by loosening hose clamps -2- and -5-.

CAUTION:

Hose Connectors -3- On Vehicles Must Not Be Opened.

-- Disconnect electrical connector -2- on Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- and remove vacuum hose -1-.

Fig 4: Disconnecting Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 Electrical Harness Connector

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-- Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- from bracket and lay aside with hose connected.

-- Disconnect the fuel lines -1 and 4- on the high pressure pumps.

Fig 5: Disconnect the Fuel Supply Line -arrow- at the Distribution Pipe on Engines with Plastic Intake Manifolds.

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-- Remove bolts -2 and 3-.

-- Disconnect electrical connection -1- at Throttle Valve Control Module -J338-.

Fig 6: Disconnecting Electrical Connection At Throttle Valve Control Module J338 & Removing Bolts And Throttle Valve Control Module J338

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-- Remove bolts -arrows- and remove Throttle Valve Control Module -J338-.

-- Disconnect vacuum lines -arrows- to brake booster.

Fig 7: Disconnecting Vacuum Lines To Brake Booster

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-- Lay vacuum lines aside.

NOTE:

Ignore -1-.

WARNING:

Cover Cap Of Coolant Expansion Tank With Rag And Open Carefully, As Hot Steam Or Hot Coolant May Escape When Opening.

-- Open cap of coolant expansion tank.

-- Remove crankcase ventilation house at placed marked with -1- and -2- by pressing release buttons.

Fig 8: Removing Crankcase Ventilation Hose, Bolts & Oil Drain Hose

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-- Clamp off the coolant hose -4- with a Hose Clamps Up to 25 mm diameter:3094 and remove the coolant hose from connection on the intake manifold.

-- Loosen bolt -5- several turns.

-- Remove bolts -3- and press crankcase ventilation pressure control valve carefully off intake manifold supports.

NOTE:

Disregard -arrow-.

To improve clarity, the removed engine is shown from the rear.

NOTE:

Place A Cloth Under Intake Manifold Supports To Collect Escaping Coolant.

-- Remove coolant hose -arrow- and lay it aside.

-- Remove vacuum hose -arrow- to intake manifold supports.

Fig 9: Removing Vacuum Hose To Intake Manifold Supports

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-- Remove the intake manifold bolts in sequence -16 to 1-.

Fig 10: Identifying Intake Manifold, Tightening Specification & Sequence

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-- Remove intake manifold from engine compartment.

NOTE:

Plug The Intake Ports Of The Cylinder Head With Clean Rags.